Topic: Another 550 with GSXR front end

[jpfrk2001]

Ok all. I guess I have enough pics to keep you all entertained to post this. A few people been asking when I was going to post the thread. I kinda kept it down low till I had enough pics for the intro. I have been slowly chipping away at this. Being very methodical in my parts I choose. Or which direction I was going to take the build.

I understand with builds like this, I have to always plan 5 steps ahead to fully understand what I need to do "Now" in the build. Constantly planning, evaluating my plans, change plan as needed. In the meantime of collecting parts, I have my CB750 to ride and now my newly acquired Ducati Monster 1100.

This build started from seeing you all building these awesome  bikes. You all infected me with this sickness. Its all your fault!!

Im not new to turning a wrench or building something from scratch. I just want to build a bike from the frame up and enjoy it. I do have another project in the other bay I am taking a break from, now that I am riding and building bikes. So with that all being said, here is what I started with:


With that and a box of parts, I started my research on what to get. Here is what I used:


More research made me make a decision to get Cognito Moto involved. So I called him up and we chatted and compared tech info based on the above chart I had with his info/charts he had. Right then I decided that one of his hubs will be used. So with that done, Its off to find a front end. I picked this up off Ebay for a decent price. Triple and upper was included along with calipers:


The rest of it:


I then got my bearing kit from Alls Balls racing. with that in hand, I had enough to start mock up:


After the motor was in its home, It was time to place it on a small little table I whipped up in a matter of minutes:

I have to use my engine hoist as there was No one around to help me. I have become rather good at figuring out how to do everything on my own with no assistance.

[jpfrk2001]

So with that all done up, time to layout my work bench. First step was to work on the lower tree and remove the lower bearing race from the stem for the alls balls stuff. This by all means was a quick job. I was scared to death of ruining the lower tree trying to get the race off. So I commenced to soaking it in PB Blaster every day for about 4 days straight. Spray it in the morning before work, spray in the evening when I get home. Repeat 3 more days straight. I have a 20 ton press in my shop at my disposal and some bearing puller clamps. So, rigged it all up in the press, double checking my set up, apply about 40lbs of initial force, check for alignment and straightness of everything. Say a prayer and slowly apply force. I fully relize I am working with aluminum, and it is soo easy to destroy. I heard a quick little "Pop" and noticed the lower race released and I could see a small gap. Woohoo!! all is good:


Did my first round of getting nuts and bolts of various sizes:


Pressed on the New lower bearing and spacer's. And mated the front end to the frame:


This is where I started getting a little giddy and I could see my end product of what she going to look like:

Notice that's with the stock OEM clip ons.

different angle:


And a different angle with tank placed on to get a idea. Electronics board in place also:

I think I am going to use the OEM location for all electronics and side covers. I relize mostly everyone goes for a pure stripped look. Im going for more of a full bodied look, but still bare Café style.

[jpfrk2001]

Next up was to get the front light bucket in place:


And a different angle. Notice the front master cylinder. That came from a Hayabuse bike:


Workbench is slowly becoming a mess:


Started to work on the headlight adjustment screw assembly:

I ended up using a spring from a ballpoint pen! who would of thought.

Pic with light installed:


Threw on the rear swing arm and rear wheel:


Over all shot:

I welded up some rear bars to mimic rear shock lengths at un sprung condition.

started collecting more parts. I got some CB750 rear shocks for mock up only. And some brand new grips. I will let the grip color let you all vision the color of the frame:

Electrical controls came from a 1996 CBR900RR.

[jpfrk2001]

One more picture shot of what is coming about:


Box of parts. New Clutch cable. New throttle cables. Some odds and ends here and there:


Some uber bling here! Front hub from Cognito Moto:

I already have brand new bearings and OEM GSXR spacers on the axle.

Complete rear wheel assembly from a 2009 Harley:

I will de-lace this. I only need the rim. It measures 17" X 4.5". I'll send this off to get laced to the 550 rear hub.

And I started working on the Carb assembly:

This has really slowed me down. Constant soaking and cleaning before tear down. I don't want to break any delicate pieces here. This my be one of the longest carb rebuilds I have done!! I already have all the solvents and cleaners to do this(I hope). Rebuild kits came from Japan.

And, My newly acquired Duc (pronounced duck):

So with this and my CB750, I have enough to keep a wide grin going.

And this is where I am at the present time. I hope I can truelly deliver a awesome build for you all to comment on and for me to enjoy riding this soon.

[Tews19]

Nice project! I have the same front end set up minus cognito's hub. Keep the updates coming

[jpfrk2001]

thanks Tew, I'll try. That's all I have as of now. Still waiting on the front wheel assembly to get here.

Any one need a complete front wheel assembly with disk brake for a 78 CB550? I won't be using any of it. Its up for grabs for a decent offer.

[calj737]

Check the Parts Wanted section. There's many folks looking for stock parts there.

[RodPlunger]

Nice start... Were you able to just slip the new fork assembly in with new bearings? Or was there a whole lot more involved?

[jpfrk2001]

Nice start... Were you able to just slip the new fork assembly in with new bearings? Or was there a whole lot more involved?

It was a pure slip on job. Just had to make sure the spacers were placed right.

[jpfrk2001]

Got a large box in the mail today! pics to come.

[Cragdog]

Cool thread! Keep the pics coming 

[PGF550F]

Very Nice set up!! I soo want to put an inverted front end on my 550. Are you planning on using the stock width front rim with that new hub? I want to do one of these swaps and just keep it simple by using a complete front end(tire, brakes, ect.) and just leave the rear stock.

Pics are awesome... Your workspace has me jealous. Great looking setup.

[jpfrk2001]

Cool thread! Keep the pics coming 

Thanks.

Very Nice set up!! I soo want to put an inverted front end on my 550. Are you planning on using the stock width front rim with that new hub? I want to do one of these swaps and just keep it simple by using a complete front end(tire, brakes, ect.) and just leave the rear stock.

Pics are awesome... Your workspace has me jealous. Great looking setup.

Thanks, Its too bad i pay rent. I was going to buy the place.

I am using the front hub from Cognito moto. Its a specially designed hub spun out of Aircraft aluminum Billet. It is machined to the size of GSXR wheels to fit the front end's OEM axle/bearings/spacers, and GSXR front Brake rotors and caliper's. But it has the provision to run 40 spoke front rims to keep the authentic look going.

The box I got in the mail is a front 17" wheel assembly off a harley. I have to delace, send the hub and rim to buchanins to get laced. I trust they can do it because they have done these exact setups before and understand the "inside/inside" lacing requirement. This is for clearing the front Brake rotors.

[K_Kalynuik]

DAMN! I wish I had seen or heard of that Hub from Cognito Moto when I built my GSXR front end CB550. Woulda saved me a lot of headaches and about 500$ in custom parts I had to have machined to make my Harley hub work with the GSXR front end. They have a lot of other nice parts as well for the conversion I see. I really like the triple clamps.

[ISLAND CAFERACERS]

great build you have going there I have the same front end & all balls bearing conversion

can you help by letting me know the sequence of spacers / bearings etc on the stem when you fitted the front end

many thanks keep up the good work Andy in the UK

[TheAngryTexan]

This sounds like a great bike in the making. That front end set-up looks gorgeous too..

[jpfrk2001]

DAMN! I wish I had seen or heard of that Hub from Cognito Moto when I built my GSXR front end CB550. Woulda saved me a lot of headaches and about 500$ in custom parts I had to have machined to make my Harley hub work with the GSXR front end. They have a lot of other nice parts as well for the conversion I see. I really like the triple clamps.

Yea, I was going to do the CBR route with custom machined axle, spacers, rotor adapters. Then I changed my mind to a GSXR front conversion when I found out about the front hub choices. Then I was comparing a front Harley hub with custom machined spacers and redrilled front rotors. Then another member said he would have done the Cognito hub instead due to cost. The hub is quite a bit upfront, but in the end, your actually saving some money as well as time.

great build you have going there I have the same front end & all balls bearing conversion

can you help by letting me know the sequence of spacers / bearings etc on the stem when you fitted the front end

many thanks keep up the good work Andy in the UK

I think I went with dust cap > spacer > lower bearing in that order from the lower tree up the stem. What I did was measure the total amount of bearing seat depth on the lower neck. Then I Measured the bearing thickness along with the spacers to get the best match. You must keep in mind the amount of thread engagement at the top tree.  I think my setup will be fine.

This sounds like a great bike in the making. That front end set-up looks gorgeous too..

Thank you.

[redrider736]

Intresting build and great info !! So much so, I bought a 08' Gx'er front end off of ebay and contacted Devin @ Cognitomoto for my 79' Cafe build
This conversion can be done to SOHC, DOHC, and all models of CB,  And expect to see the price of GX'er parts going up 

[jpfrk2001]

Working on my carbs now. Keihin PD units. Cannot remove the slider/needle assembly from body!!!!

And I still owe you all some pics to come.

[jpfrk2001]

Redrider, thanks for the kind words.

Here are some pics I promised you all. I had no choice but to start destroying the OEM rubber boots to separate the intake manifolds from the Carb assembly:


Progress pic:


Finally separated for further tear down:



Finally got the number 1 off. Also, decided to slow down and take some reference pics So I can put it all back together. I already have the number 1 fully torn down and parts soaking in assorted cocktail mixes to clean. I was able to remove the slider assembly and get the needle separated from the slider. But I managed to destroy on of the small screws. So, I had to go find some replacement stuff. The only things I could find was Panhead allen screws.

Size is: M3 x .50 x 8 MM

Just for your information. I was lucky I didn't destroy the slider getting that old bugger out!! I had to drill out the screw from the underside. And to get the best setup for the drill, I had to cut the needle. I have replacements.

And pics of the front and rear wheels side by side.


I will prep the front rim after tear down for gloss black to match the rear rim. I will also clean, prep, and paint the rear 550 hub to match the front hub gloss black. Plan is to send these to Buchanan for lace up.

But for know, its off to battle with carburators. Slow build I can see coming.

[jpfrk2001]

Hoping to finish 1 of 4 carbs tomorrow. Have not even started on the second one yet. The Body is still soaking in a Vinigar/simple green solution right now.

[jpfrk2001]

Well, this may be my last update going into the new year. I leave tomorrow to spend time with family. I won't be back till around the 3rd.  So I will leave off with pics of the first of 4 carbs are finally cleaned. It was a painstaking amount of patience. Between work, eat, sleep, I really have minimul amount of time to put into this. Besides, I don't have all the parts needed to get this bike into a roller. So I am really in no rush. Today is clean house, pack, Go ride both bikes and put in my shop. Lock up the shop, and other things.

So with that, here are two updated pics. The first one is the final step in cleaning the carb. I mixed up a mixture of 15% Simple Green to 85% distalled vinegar. I then brought into the house and placed in my sink. I then filled up the sink with extremely hot water.

The idea was that the hot water would heat up the mixture in the container and help it out. I then took a tooth brush and went to work this morning along with Q-tips to get in those small areas.

This is what came out:

I would say not to bad for what I started with!! Battling 36 years of gunk. Still not done. The gasket for the float bowl does NOT want to come out. Its acting as its superglued or something to the bowl. Not to mention its hard as a rock!! I'll figure something out. I may take the bowl with me and discuss with my father and Brother Inlaw. Between us 3, we should be able to figure something out.

So, January's goal is finish the entire carb assembly. Start figuring out wiring and see if I can get the engine to fire up and idle in February. Sync carbs next if that happens. Not to mention, start working on the front and rear wheel assemblies to be sent off to Buchanan's for lace up.

Merry Christmas all!!

[run-tmc]

JP, I'm loving this thread. Great build pics!


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[jpfrk2001]

JP, I'm loving this thread. Great build pics!


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thanks.

Right now Im battling the o-ring removel from all 4 carb bowls. Those things don't want to come out. I've tried all sorts of methods. The rubber O-rings are hard as a rock and can't even get a sharp razor to slice them up.

Any one have any idea or suggestions?

Im soaking one I brought with me to my sister's house to see if my Dad and Brother Inlaw had any insight. My dad said use Acetone as one way. I know that stuff is nasty as ever. Will it harm the aluminum housing and brass vent tube?

Any one?

[Tews19]

I use one of those little screw drivers to remove the hard o rings on the jets. I gave it a whack and they crumbled in pieces. No harm was done.